Ac/dc converter with inrush current limitation

ABSTRACT

An AC/DC converter includes: a first terminal and a second terminal for receiving an AC voltage and a third terminal and a fourth terminal for supplying a DC voltage. A rectifying bridge includes input terminals respectively coupled to the first terminal and the second terminal, and output terminals respectively coupled to the third terminal and fourth terminal. A first branch of the rectifying bridge includes, connected between the output terminals, two series-connected thyristors with a junction point of the two thyristors being connected to a first one of the input terminals. A second branch of the rectifying bridge is formed by series connected diodes. A control circuit is configured to generate control signals for application to the control gates of the thyristors.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/956,482 filed Dec. 2, 2015, which claims the priority benefit ofFrench Application for Patent No. 1552985, filed on Apr. 7, 2015, thedisclosures of which are hereby incorporated by reference in theirentireties.

TECHNICAL FIELD

The present disclosure generally relates to electronic devices and, morespecifically, to AC/DC converters. The present disclosure generallyapplies to any system using a rectifying bridge, for example, circuitsfor controlling electric motors, electric chargers, switched-mode powersupplies, etc.

BACKGROUND

Many AC/DC converter architectures based on rectifying elements areknown, which may be controllable (thyristors, for example) or not(diodes, for example), assembled as a rectifying bridge, powered with anAC voltage and delivering a DC voltage, this DC voltage being possiblyitself converted back into an AC voltage.

The inrush current, that is, the current peaks which occur on eachhalfwave of the AC voltage as long as the voltage across a capacitor atthe output of the rectifying bridge has not reached a sufficient levelis generally desired to be limited and this, particularly, in startingphases.

United States Patent Application Publication No. 2012/0230075(incorporated by reference) describes an example of an AC/DC converter.

SUMMARY

An embodiment overcomes all or part of the disadvantages of usual powerconverter control circuits.

An embodiment aims at providing a circuit for limiting the inrushcurrent in a power converter.

An embodiment provides a solution compatible with a voltage-doublingfunction at the level of a rectifying bridge powered with the ACvoltage.

Thus, an embodiment provides an AC/DC converter comprising: a firstterminal and a second terminal, intended to receive an AC voltage; athird terminal and a fourth terminal, intended to supply a first DCvoltage; a rectifying bridge having input terminals respectively coupledto the first terminal and connected to the second terminal, and havingoutput terminals respectively connected to the third and fourthterminals, a first branch of the bridge comprising, between the outputterminals, two series-connected thyristors, respectively with an anodegate and a cathode gate, the junction point of the two thyristors beingconnected to a first one of said input terminals and the anode gatethyristor being controllable by extraction of a current from its gate.

According to an embodiment, a second branch of the bridge comprises afirst diode and a second diode series-connected between the outputterminals, the junction point of the diodes being connected to a secondone of said input terminals.

According to an embodiment, the cathode-gate thyristor is controlled byinjection of a current into its gate.

According to an embodiment, the thyristors are both controlled byextraction of a current from their gate.

According to an embodiment, the thyristors are controlled by a samepulse signal.

According to an embodiment, the thyristors are phase-angle controlled.

According to an embodiment, two series-connected capacitive elementscouple the third and fourth terminals, a switch connecting the junctionpoint of the capacitive elements to the second terminal.

According to an embodiment, the gates of the thyristors are controlledby a same transformer, excited by an AC signal.

According to an embodiment, the thyristor gates are controlled by a sametransformer, excited by a periodic square-wave positive and negativesignal.

According to an embodiment, the converter further comprises: atransformer for generating, from at least a third diode connected to thefirst one of said input terminals, a first DC voltage for powering acircuit for controlling the thyristors and a second DC voltage appliedto said first one of the input terminals.

In an embodiment, an AC/DC converter comprises: a first terminal and asecond terminal configured to receive an AC voltage; a third terminaland a fourth terminal configured to supply a first DC voltage; arectifying bridge having input terminals respectively coupled to thefirst terminal and second terminal, and having output terminalsrespectively coupled to the third terminal and fourth terminal, whereinthe rectifying bridge includes a first branch comprising a firstthyristor and a second thyristor, respectively having an anode gate anda cathode gate, that are series connected between the output terminals,a junction point of the first and second thyristors being connected to afirst one of the input terminals; and a controller coupled to the anodegate and configured to generate control pulses that turn on the firstthyristor, wherein timing of the control pulses progressively increasesa conduction time of the first thyristor over a time period time tocontrol inrush current.

In an embodiment, an AC/DC converter comprises: a first terminal and asecond terminal configured to receive an AC voltage; a third terminaland a fourth terminal configured to supply a first DC voltage; arectifying bridge having input terminals respectively coupled to thefirst terminal and second terminal, and having output terminalsrespectively coupled to the third terminal and fourth terminal, whereinthe rectifying bridge includes a first branch comprising a firstthyristor and a second thyristor, respectively having an anode gate anda cathode gate, that are series connected between the output terminals,a junction point of the first and second thyristors being connected to afirst one of the input terminals; and a controller configured togenerate first control pulses coupled to the anode gate that turn on thefirst thyristor and generate second control pulses coupled to thecathode gate that turn on the second thyristor, wherein timing of eachof the first and second control pulses progressively increases aconduction time of the first and second thyristors, respectively, over atime period time to control inrush current.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages will be discussed indetail in the following non-limiting description of specific embodimentsin connection with the accompanying drawings, wherein:

FIG. 1 schematically shows an example of a usual architecture of anAC/DC converter equipped with an inrush current limiting circuit;

FIG. 2 schematically shows a modification of the assembly of FIG. 1 toform a voltage-doubling converter;

FIG. 3 schematically shows an embodiment of an AC/DC converter;

FIG. 4 is a partial electric diagram of an embodiment of a circuit forcontrolling the converter of FIG. 3;

FIG. 5 is a simplified cross-section view of an embodiment of acathode-gate thyristor having a positive gate current;

FIG. 6 is a simplified cross-section view of an embodiment of acathode-gate thyristor having a negative gate current;

FIGS. 7A, 7B, 7C, and 7D illustrate, in timing diagrams, the operationof the converter of FIG. 3, in voltage doubling mode;

FIGS. 8A, 8B, 8C, and 8D illustrate, in timing diagrams, the operationof the converter of FIG. 3, in follower mode;

FIG. 9 shows another embodiment of a converter; and

FIG. 10 partially shows a converter control element.

DETAILED DESCRIPTION

The same elements have been designated with the same reference numeralsin the different drawings. In particular, the structural and/orfunctional elements common to the different embodiments may bedesignated with the same reference numerals and may have identicalstructural, dimensional, and material properties. For clarity, onlythose steps and elements which are useful to the understanding of thedescribed embodiments have been shown and will be detailed. Inparticular, the circuits powered by the power converter have not beendetailed, the described embodiments being compatible with usualapplications. In the disclosure, term “connected” designates a directconnection between two elements, while terms “coupled” and “linked”designate a connection between two elements, which may be direct or viaone or a plurality of other elements. When reference is made to terms“about”, “approximately”, or “in the order of”, this means to within10%, preferably to within 5%.

FIG. 1 schematically shows an example of an architecture of an AC/DCconverter equipped with an inrush current limiting circuit.

Two input terminals 12 and 14 are intended to receive an AC voltage Vac,for example, the voltage of the electric distribution network (forexample, 230 or 120 volts, 50 or 60 Hz). Terminal 12 is coupled, via aninrush current limiting assembly 2, to a first rectifying input terminal32 of a rectifying bridge 3 (for example, fullwave) having its secondrectifying input terminal 34 connected to terminal 14. Rectified outputs36 and 38 of the bridge are respectively connected to output terminals16 and 18, delivering a DC voltage Vdc. A storage and smoothingcapacitor C0 couples terminals 16 and 18. The inrush current limitingassembly is formed of a resistor 22, coupling terminals 12 and 32, andof a switch 24 which may be controlled to short-circuit resistor 22. Atthe starting (capacitor C0 discharged), switch 24 is turned off andresistor 22 limits the charge current of capacitor C0. In steady state,switch 24 is turned on to short-circuit the resistor and to limitlosses.

More sophisticated solutions use, between an input terminal ofapplication of the AC voltage and the rectifying bridge, a device forcontrolling the bridge turn-on phase angle, that is, for selecting thetime, for each halfwave of the AC voltage, from which the rectifyingbridge is powered. In such a case, the starting of the converterrequires a voltage source to power a circuit for controlling the phasecontrol switch. Current solutions often use complex assemblies.

FIG. 2 schematically shows a modification of the assembly of FIG. 1 toform a voltage-doubling converter. Terminal 34 is coupled, via a switch21, to a junction point of two capacitive circuit elements (capacitorsC01 and C02) connecting terminals 16 and 18 (with the possibility ofsuppressing capacitor C0). Assuming that capacitive elements C01 and C02have the same capacitance, voltage Vdc between terminals 16 and 18corresponds, in steady state, to twice peak voltage Vac betweenterminals 12 and 14.

In the assembly of FIG. 1, the presence of switch 24 generates losses insteady state. In practice, this switch may be formed by a triac and thelosses are due to the on-state series resistance of this triac.

FIG. 3 schematically shows an embodiment of an AC/DC converter.

It shows a rectifying bridge having input terminals 32 and 34 coupledwith first and second terminals 12 and 14 of application of an ACvoltage Vac and having rectified output terminals 36 and 38 connected tothird and fourth terminals 16 and 18 for supplying a DC voltage Vdc. Atleast one capacitive element interconnects terminals 16 and 18. In theexample of FIG. 3, an inductive circuit element (inductor L) isinterposed between a terminal of delivery of voltage Vac (here, terminal12) and the bridge.

However, unlike the rectifying bridge of FIG. 1, rectifying bridge 3 ishere formed of two controllable thyristor-type rectifying elements Th1and Th2 connected in a branch of the bridge, that is, in series betweenterminals 36 and 38. In the example of FIG. 3, thyristor Th1, which hasan anode gate, connects terminal 32 to terminal 36 with its anode on theside of terminal 32, while thyristor Th2, which has a cathode gate,connects terminal 38 to terminal 32 with its anode on the side ofterminal 38. Two diodes D33 and D35 complete the bridge by respectivelycoupling terminal 34 to terminal 36 and terminal 38 to terminal 34, theanodes of diodes D33 and D35 being respectively on the side of terminal34 and on the side of terminal 38.

In the example of FIG. 3, a converter capable of operating involtage-doubling mode or in follower mode is assumed. Accordingly, twocapacitive circuit elements (capacitors C01 and C02 of same capacitancevalue) series-connected between terminals 16 and 18 and an element 21(for example, a jumper, a switch, a relay, etc.) connecting junctionpoint 44 of capacitive elements C01 and C02 to terminal 14 (and thus toterminal 34) are provided. When connection 21 is open (no connectionbetween terminal 14 and node 44), bridge 3 operates in follower mode,that is, the maximum value of voltage Vdc corresponds to the peak valueof voltage Vac (to within losses). When connection 21 is active, theconverter operates in voltage-doubling mode, that is, the maximum valueof voltage Vdc corresponds to twice the peak value of voltage Vac.

Thyristors Th1 and Th2 are controlled by an electronic circuit, forexample, a microcontroller 26, in charge of generating pulses forcontrolling thyristors Th1 and Th2 and controlling the gates of thesethyristors via one or two insulated couplers (not shown in FIG. 3), ofoptical, magnetic, or capacitive technology. Microcontroller 26 receivesdifferent set points CT or measurements to generate the pulses at theright times according, among others, to the needs of the load powered bythe converter.

FIG. 4 partially shows an embodiment of a circuit for controllingthyristors Th1 and Th2 of the assembly of FIG. 3.

Thyristors Th1 and Th2 are selected so that their control is referencedto the same point. Thus, thyristor Th1 is an anode-gate thyristor. Itscontrol is thus referenced to terminal 32. Thyristor Th2 is acathode-gate thyristor. Its control is thus referenced to the sameterminal 32.

In the embodiment of FIG. 4, thyristors Th1 and Th2 are selected torespectively operate by gate current extraction and by gate currentinjection.

In the circuit of FIG. 4, a first winding L41 of a transformer 4receives a pulse control from a microcontroller 26 powered with a DCvoltage Vcc. The other end of winding L41 is coupled to the junctionpoint of two capacitive elements C43 and C44 between power supplyterminal Vcc and the ground. A second winding L42 of transformer 4 hasone end connected to terminal 32 and its other end coupled to the gatesof thyristors Th1 and Th2. This coupling is performed via an optionalseries resistor R45 and two diodes D46 and D47 respectively connectingwinding L42 (or resistor R45) to the gates of thyristors Th1 and Th2.The anode gate of thyristor Th1 is coupled to the anode of diode D46while the cathode gate of thyristor Th2 is connected to the cathode ofdiode D47, the cathode of diode D46 and the anode of diode D47 beingconnected to winding L42 (or to resistor R45).

The circuit of FIG. 4 thus enables to both inject a gate current intothyristor Th2, and to extract a gate current from thyristor Th1. The twothyristors are thus controlled each time an AC pulse (of +Vcc/2−Vcc/2type) is applied to primary L41 of transformer 4.

If the two controls are desired to be distinguished, for example, byonly controlling thyristor Th1 during positive halfwaves of voltage Vac,and only controlling thyristor Th2 during negative halfwaves of voltageVac, this is possible by applying across L41 respectively during thesetwo types of halfwaves, a signal of type −Vcc/0 (to turn on thyristorTh1), and a signal of type +Vcc/0 (to turn on thyristor Th2). Since suchsignals have a DC component, transformer 4 should not have a saturablemagnetic material to avoid the saturation of this material and ensurethe proper operation of the control signal transfer. A transformer withno magnetic core (or “air transformer”) may thus for example be used.

According to another embodiment, thyristors Th1 and Th2 are selected toboth operate by extraction of current from their gate. Thus, a sameso-called negative power supply voltage Vdd (that is, having its highlevel, VDD, connected to terminal 32, itself coupled to terminal 12 ofthe mains) is sufficient to power the two thyristors Th1 and Th2. Thissame power supply may be used to power the gates of triacs having theircontrol reference connected to terminal 32. Such triacs would be usefulto control AC current loads powered with voltage Vac.

The achieving of a function of cathode-gate thyristor controllable bycurrent extraction is known. A triac series-connected with a diode to bemade unidirectional may for example be used.

FIGS. 5 and 6 are simplified cross-section views of embodiments ofcathode-gate thyristors, respectively with a positive gate current or acurrent injection (most current case) and with a negative gate currentor a current extraction.

According to these examples, the thyristor is formed in an N-typesubstrate 51. At the rear surface, a P-type layer 52 defines an anoderegion, anode electrode A being obtained by a contacting metallization53 of region 52. A P-type well 54 is formed at the front surface. AnN-type cathode region 55 (N1) is formed in well 54 and a contactingmetallization 56 of this region 55 defines cathode electrode K.

In the case of FIG. 5, a gate contact 57 is formed at the level ofP-type well 54. Thus, the injection of a gate current turns on thethyristor if the latter is properly biased (positive anode-cathodevoltage).

In the case of FIG. 6, an N-type region 58 (N2) is added under gatecontact 57. Region 58 allows a turning-on by a negative gate current(that is, flowing from cathode K to gate G) by allowing an electroninjection into N-type substrate 51, which corresponds to the base of theNPN-type bipolar transistor formed by regions 52-51-54.

As a variation, region 58 may be divided at least in two to allow adirect contact of the P region (54) with the gate. Such a variation,called “short-circuit hole”, enables to improve the immunity to voltagetransients of the thyristor and thus allows the control by a positivegate current (that is, flowing from gate G to cathode K). Such avariation thus enables the thyristor to be used at the level ofcomponent Th2 in the circuit of FIG. 4.

To achieve the inrush current limiter function at the starting of theconverter, the use of thyristors makes a phase angle control possibleand thus enables to progressively increase the thyristor conduction timeto ensure a positive charge of the capacitors connected betweenterminals 36 and 38 and thus limit the inrush current absorbed betweeninput terminals 12 and 14 at the circuit powering on.

FIGS. 7A, 7B, 7C, and 7D illustrate, in timing diagrams, the operationof the converter of FIG. 3, in the embodiment where thyristors Th1 andTh2 both operate by extraction of current from their gate, involtage-doubling mode (switch 21 on). These drawings illustrate theoperation at the starting of the converter, that is, as long as voltageVdc has not reached its steady state value, approximately twice the peakvalue of voltage Vac (approximately 320 volts). FIG. 7A shows examplesof shapes of voltage Vac. FIG. 7B illustrates the shape of current IL ininductance L. FIG. 7C illustrates the shapes of gate voltages V_(GT) ofthyristors Th1 and Th2 (one peak out of two corresponding to each of thethyristors) with timing of the control pulses at the thyristor gatescausing a progressive increase in conduction time of the thyristors overa time period time to control inrush current. FIG. 7D illustrates theshape of the obtained voltage Vdc.

In the example of FIGS. 7A to 7D, a voltage Vac of 320 volts,peak-to-peak, with a 50-Hz frequency, is assumed.

FIGS. 8A, 8B, 8C, and 8D illustrate, in timing diagrams, the operationof the converter of FIG. 3, in the embodiment where thyristors Th1 andTh2 both operate by extraction of current from their gate, in followermode (switch 21 off). These drawings illustrate the operation at thestarting of the converter, that is, as long as voltage Vdc has notreached its steady state value, approximately twice the peak value ofvoltage Vac (approximately 320 volts). FIG. 8A shows examples of shapesof voltage Vac. FIG. 8B illustrates the shape of current IL ininductance L. FIG. 8C illustrates the shapes of gate voltages V_(GT) ofthyristors Th1 and Th2 (one peak out of two corresponding to each of thethyristors) with timing of the control pulses at the thyristor gatescausing a progressive increase in conduction time of the thyristors overa time period time to control inrush current. FIG. 8D illustrates theshape of the obtained voltage Vdc.

In the example of FIGS. 8A to 8D, a voltage Vac of 640 volts,peak-to-peak, with a 50-Hz frequency, is assumed. The amplitude ofvoltage Vdc obtained in follower mode (FIG. 8D) thus is approximately320 volts as in FIG. 7D.

The phase angle control of thyristors Th1 and Th2, by being turned on inphases of decrease of rectified voltage Vac, according to the capacitorcharge level, effectively enables to limit inrush currents at thestarting by performing a soft start as shown in FIGS. 7 and 8.

In the representation of FIGS. 7B and 8B, the amplitudes of current ILaccording to the halfwaves depend on the downstream power consumption ofthe converter and illustrate an arbitrary example.

FIG. 9 shows another embodiment of an AC/DC converter.

As compared with the embodiment of FIG. 3, a circuit 9 for generating avoltage VDD2 to be applied to terminal 32 is provided. Voltage VDD2 isgenerated by a transformer 91 generating, from a first winding L92, twoDC voltages VDD1 and VDD2 across two coupled windings L93 and L94(winding L93 being coupled to winding L92 and winding L94 being coupledto winding L93). A diode D1 couples terminal 32 to winding L92 (anode onthe side of terminal 32) having its other end coupled to terminal 18(and thus terminal 38) by an electronic control circuit 95 generallyintegrating a MOSFET transistor, which controls the current of windingL92 in switched mode. One end of winding L93 is coupled by a diode D96(anode on the winding side) to terminal 32. Its other end forms thereference of voltage VDD2. One end of winding L94 is coupled by a diodeD97 (anode on the winding side) to a terminal 98 providing voltage VDD1.The other end of winding L94 is connected to terminal 18 and a capacitorC99 couples terminals 98 to 18. A diode D2 may couple terminal 14 towinding L92 to power circuit 95 from a fullwave rectification when Th2is made conductive by control circuit 26 of FIG. 3.

Such an embodiment enables to limit the inrush current if thyristors Th1and Th2 are controlled in phase angle to achieve the soft startfunction.

In FIG. 9, a capacitor C0 is further placed in parallel with the seriesassociation of capacitors C01 and C02.

FIG. 10 illustrates, in a partial diagram, an example of control ofthyristors Th1 and Th2 by pulses generated by the microcontroller. Thegates of thyristors Th1 and Th2 are coupled, by resistors R3 and R4, tothe collector of an optotransistor of an optocoupler 4 having itsemitter connected to ground. A photodiode of optocoupler 4 is excited bypulses by microcontroller 26.

Various embodiments have been described. Various alterations,modifications, and improvements will occur to those skilled in the art.For example, the thyristors may be replaced with triacs, eachseries-connected with a diode. Further, the practical implementation ofthe embodiments which have been described is within the abilities ofthose skilled in the art based on the functional indications givenhereabove. In particular, the programming of the microcontroller dependson the application and the described embodiments are compatible withusual applications using a microcontroller or the like to control aconverter.

Such alterations, modifications, and improvements are intended to bepart of this disclosure, and are intended to be within the spirit andthe scope of the present invention. Accordingly, the foregoingdescription is by way of example only and is not intended to belimiting. The present invention is limited only as defined in thefollowing claims and the equivalents thereto.

1. An AC/DC converter, comprising: a first terminal and a secondterminal configured to receive an AC voltage; a third terminal and afourth terminal configured to supply a first DC voltage; a rectifyingbridge having input terminals respectively coupled to the first terminaland second terminal, and having output terminals respectively coupled tothe third terminal and fourth terminal, wherein the rectifying bridgeincludes a first branch comprising a first thyristor and a secondthyristor, respectively having an anode gate and a cathode gate, thatare series connected between the output terminals, a junction point ofthe first and second thyristors being connected to a first one of theinput terminals; and a controller coupled to the anode gate andconfigured to generate control pulses that turn on the first thyristor,wherein timing of the control pulses progressively increases aconduction time of the first thyristor over a time period time tocontrol inrush current.
 2. The converter of claim 1, wherein the firstthyristor is controllable by extraction of current from the anode gate.3. The converter of claim 1, wherein the rectifying bridge furtherincludes a second branch comprising a first diode and a second diodethat are series-connected between the output terminals, a junction pointof the first and second diodes being connected to a second one of saidinput terminals.
 4. The converter of claim 1, wherein the secondthyristor is controlled by injection of current into the cathode gate.5. The converter of claim 1, wherein the first and second thyristors areboth controlled by extraction of current from the anode gate and cathodegate respectively.
 6. The converter of claim 1, wherein the controlpulses are applied to both the anode gate of the first thyristor and thecathode gate of the second thyristor.
 7. The converter of claim 1,wherein the timing of the control pulses provides phase-angle control ofthe first thyristor.
 8. The converter of claim 1, further comprising: afirst capacitor and a second capacitor series-connected between thethird and fourth terminals, and a switch that connects a junction pointof the first and second capacitors to the second terminal.
 9. Theconverter of claim 1, wherein a frequency of the control pulsesprogressively increases over said time period.
 10. An AC/DC converter,comprising: a first terminal and a second terminal configured to receivean AC voltage; a third terminal and a fourth terminal configured tosupply a first DC voltage; a rectifying bridge having input terminalsrespectively coupled to the first terminal and second terminal, andhaving output terminals respectively coupled to the third terminal andfourth terminal, wherein the rectifying bridge includes a first branchcomprising a first thyristor and a second thyristor, respectively havingan anode gate and a cathode gate, that are series connected between theoutput terminals, a junction point of the first and second thyristorsbeing connected to a first one of the input terminals; and a controllerconfigured to generate first control pulses coupled to the anode gatethat turn on the first thyristor and generate second control pulsescoupled to the cathode gate that turn on the second thyristor, whereintiming of each of the first and second control pulses progressivelyincreases a conduction time of the first and second thyristors,respectively, over a time period time to control inrush current.
 11. Theconverter of claim 10, wherein the first and second control pulses areinterleaved.
 12. The converter of claim 10, wherein the first thyristoris controllable by extraction of current from the anode gate.
 13. Theconverter of claim 10, wherein the rectifying bridge further includes asecond branch comprising a first diode and a second diode that areseries-connected between the output terminals, a junction point of thefirst and second diodes being connected to a second one of said inputterminals.
 14. The converter of claim 10, wherein the second thyristoris controlled by injection of current into the cathode gate.
 15. Theconverter of claim 10, wherein the first and second thyristors are bothcontrolled by extraction of current from the anode gate and cathode gaterespectively.
 16. The converter of claim 10, wherein the timing of thefirst and second control pulses provides phase-angle control of thefirst second thyristors, respectively.
 17. The converter of claim 10,further comprising: a first capacitor and a second capacitorseries-connected between the third and fourth terminals, and a switchthat connects a junction point of the first and second capacitors to thesecond terminal.
 18. The converter of claim 10, wherein a frequency ofthe first and second control pulses progressively increases over saidtime period.